Process for making sound insulation components

C - Chemistry – Metallurgy – 04 – B

Patent

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18/1013

C04B 43/02 (1980.01)

Patent

CA 1107929

PROCESS FOR MAKING SOUND INSULATION COMPONENTS Abstract of the Disclosure A process for making composite contoured sound insulating panels of a type suitable for use adjacent to structural panels of automobile vehicle bodies, which in accordance with one embodiment of the present invention, comprises forming a fibrous pad incorporating controlled amounts of a heat curable thermosetting binder and a heat softenable thermoplastic binder distributed in a controlled manner therethrough. The pad is subjected to a preliminary curing step to bond the fibers together into an integral mass, whereafter a dense liquid vinyl plastisol coating is applied to at least one face surface of the pad, which thereafter is heated to effect a fusion of the coating into a heat softened integral layer, effecting a simultaneous heat softening of the thermoplastic binder, whereafter the heated pad is placed between appropriately contoured mold surfaces and is compressed to impart a preselected contour thereto and localized emboss- ments therein and a desired surface finish to the plastisol layer, while simultaneously cooling the pad to effect a rigid- ification of the thermoplastic binder and the layer so as to retain the composite pad in the preselected contoured and em- bossed configuration. In accordance with an alternative em- bodiment of the disclosed process, the pad is subjected to a preliminary molding step, followed by the coating step, and is subjected to a final molding step after the plastisol coat- ing has been fused at an elevated temperature. The step of molding the plastisol layer is performed employing a subat- mospheric pressure to achieve improved definition in the contour and texture of the molded face surface.

301937

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